Stacked prismatic architecture for electrochemical cell

ABSTRACT

A battery cell system and method for manufacturing a battery cell system is provided. The battery cell system includes an electrode stack including a first anode with a first anode tab, a second anode with a second anode tab laterally offset from the first anode tab, a first cathode with a first cathode tab, and a second cathode with a second cathode tab laterally offset from the first cathode tab.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a U.S. National Phase of International PatentApplication Serial No. PCT/US2018/036294 entitled “STACKED PRISMATICARCHITECTURE FOR ELECTROCHEMICAL CELL”, filed on Jun. 6, 2018.International Patent Application Serial No. PCT/US2018/036294 claimspriority to U.S. Provisional Application No. 62/520,478, entitled“STACKED PRISMATIC ARCHITECTURE FOR ELECTROCHEMICAL CELL”, and filed onJun. 15, 2017. The entire contents of each of the above-listedapplications are hereby incorporated by reference for all purposes.

FIELD

The present application relates a battery cell system and a method formanufacturing a battery cell system.

BACKGROUND AND SUMMARY

The search for cost-effective solutions to increase battery capacity isa significant challenge. As the price-per-kWh continues to drop forbattery electrochemical storage, there is a need to build larger,higher-capacity batteries which can also be used for high-powerapplications. Many types of electrochemical cells have electrodes in‘sheet’ form, wherein sheets of positive and negative electrode materialare stacked together and separated by electrically insulating porousseparator sheets. In order to increase overall capacity (e.g., totalusable energy) of the cell, close contact between sheets, or electrodes,may be desired.

A large geometric surface area may be desired for a high-power,low-impedance electrochemical cell having stacked prismatic cellarchitecture. In manufacturing a typical battery comprising a stackedprismatic cell, the stack is formed by layers of electrode cells whichmay contain lithium-ion or other electrochemical materials useful forsecondary batteries, or secondary cells. When the electrodes of theelectrode stack remain in very close contact with one another throughoutthe life of the cell, the battery can achieve a desired capacity.However, if the electrode stack achieves less than desired contactbetween sheets, then tension between sheets or between sheets and thebattery housing may arise due to gas generated within the battery duringthe cycling of the battery. In order to increase battery capacity andprovide desired electrode stacking, many solutions have been proposed.

One proposed example is shown in U.S. Pat. No. 8,133,609. Therein, abattery comprising a plurality of cells, or plates, has tabs from eachcell welded to a lead portion, and the lead portion is protected by anenclosure. Another example is shown in U.S. Pat. No. 6,159,631. Therein,a variety of scored regions located on a cell can, or housing, areprovided in order to release excess pressure over a narrow andcontrollable range, in order to avoid explosion in the event of a largebattery swell.

However, the inventors herein have identified potential issues with suchsystems related to layering of battery cells, welding of battery cells,housing manufacture and assembly, and the design and manufacture ofrelease or safety ventilation. For example, a normal battery having ahigh-power stacked prismatic cell has a plurality of layers of cells, orelectrode cells. The number of layers is limited by the weldingtechnique used to weld the tabs, or electrodes, of each layer together.In particular, the number of electrodes included in a cell is limited bythe durability of electrode tabs when exposed to the energy of welding.Thus, as the number of electrodes increases, and therefore the weldintensity needed to weld all of the electrodes increases, the electrodesmay be more susceptible to degradation (e.g., melting, deformation,etc.). For example, current manufacturing techniques utilize a largeelectrode dimension and a layer count often less than 60 layers, andtypically in the range of 20-30 layers. Additionally, the thickness of acell may be limited to 15 mm due to manufacturing limitations of thehousing.

Furthermore, the housing imposes an additional limitation ofconstraining the depth to which housing material can be formed. Oftenhousing is formed from aluminum, and the shape of the housing is formedfrom aluminum sheet metal in a similar fashion to the way in which sheetmetal is stamped. However, during conventional housing formingprocesses, the aluminum, or other housing material, is stretched and itsthickness is reduced, thereby reducing the strength of the material.Additionally, previous secondary, or rechargeable, batteries do notinclude safety valves or gas-releasing apparatus in order to deal withcatastrophic failure of one or more battery cells.

In one embodiment, some of the above issues may be at least partiallyaddressed by a battery cell system comprising an electrode stackincluding a first anode with a first anode tab, a second anode with asecond anode tab laterally offset from the first anode tab, a firstcathode with a first cathode tab, and a second cathode with a secondcathode tab laterally offset from the first cathode tab. By offsettingtabs of like polarity electrodes, the number of electrode tabs in awelded group may be reduced, if desired. As such, the number ofelectrodes included in a cell may be increased without unduly increasingthe thickness of the groups of electrode tabs. Consequently, the risk ofelectrode tab degradation (e.g., deformation, melting, etc.,) caused byincreased intensity welding may be reduced. In this way, a higher powercell with increased durability may be achieved, if desired.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an example of a prior art electrochemical cell.

FIGS. 2A and 2B show, respectively, cathodes and anodes in a batterycell system.

FIG. 3 shows coated sheet material of the anode in the battery cellsystem.

FIG. 4 shows coated sheet material of the cathode in the battery cellsystem.

FIG. 5 shows an electrode stack with interleaved tabs in the batterycell system.

FIG. 6 shows an electrode stack with trimmed tabs for welding in thebattery cell system.

FIG. 7 shows an electrode stack with welded extension tabs in thebattery cell system.

FIG. 8 shows an electrode stack with a top frame in the battery cellsystem.

FIG. 9 shows a structural frame with a stack assembly in the batterycell system.

FIG. 10 shows an electrode stack with a structural frame in the batterycell system.

FIG. 11 shows a structural frame sidewall designed for strain relief inthe battery cell system.

FIG. 12 shows a protective housing surrounding an electrode stack in thebattery cell system.

FIGS. 13A and 13B show different views of the protective housing in thebattery cell system.

FIG. 14 shows another view of the protective housing in the battery cellsystem.

FIG. 15 shows a welded electrode stack in the battery cell system.

FIG. 16 shows a pouch top with a filling or ventilation port in thebattery cell system.

FIG. 17 shows a rupture disc vent installed in the filling orventilation port in the battery cell system.

FIG. 18 shows an example of an electrode stack pattern in a battery cellsystem.

FIG. 19 shows layers of a laminate pouch in a battery cell system.

FIG. 20 shows a method for manufacturing a battery cell system.

FIGS. 2A-17 are drawn to scale, although other relative dimensions maybe used, if desired.

DETAILED DESCRIPTION

The following description relates to a battery cell system with astacked electrochemical cell battery (e.g., stacked prismaticelectrochemical cell battery) and a method for manufacturing the batterycell system. It will be appreciated that FIGS. 2A-20 may be discussedcollectively. FIGS. 2A-15 show different stages of assembly of a batterycell system 550. FIGS. 16-17 show example configurations of a protectivehousing in the battery cell system. FIG. 18 shows an example of layersan electrode stack that may be included in the battery cell system. FIG.19 shows an example of layers in a protective housing in the batterycell system. FIG. 20 shows a method for manufacturing a battery cellsystem. Furthermore, axes X, Y and Z are provided for references inFIGS. 2A-17. In one example, the Z-axis may be parallel to agravitational axis and therefore may be referred to as a vertical axis.Additionally, the Y-axis may be a lateral axis and the X-axis may be alongitudinal axis. However, the axes may have alternate orientations, inother examples.

The stacked cell battery described herein is an improvement upon FIG. 1(prior art). Prior art FIG. 1 shows an example of an electrode stack 100having a plurality of anode foil tabs 102 and cathode foil tabs 104. Asshown in FIG. 1 the anode foil tabs 102 are laterally aligned with oneanother. The cathode foil tabs are likewise laterally aligned with oneanother.

In the description herein, an anode is a positive electrode and acathode is a negative electrode. It will be appreciated that a negativeelectrode is an electrode through which conventional current leaves thedevice and a positive electrode is an electrode through whichconventional current enters the device. As such, the anodes and cathodesmay be generally referred to as electrodes, in some examples.

FIG. 3 shows an example anode 300 that may be included in an electrodestack, such as electrode stack 500 shown in FIG. 5. The anode 300 maycomprise an anode coating 302, coated onto both sides of an anodeelectrode sheet 306 designed to collect current. The anode electrodesheet 306 may comprise a metallic foil substrate, and the coating 302may comprise an electrochemically active anode material (e.g.,electro-active Lithium intercalation material) such as a mixture ofnatural and artificial graphite or Lithium-titanate, or metallicLithium. Thus, the anode 300 may comprise a metallic foil substrate(e.g., anode electrode sheet 306) that is partially or wholly coveredwith the coating 302. The coating 302 may be applied over a specificportion of the anode electrode sheet 306, such as over a specific widthof the anode electrode sheet 306, but not all of the anode electrodesheet 306, such that at least a portion of the anode electrode sheet 306may remain uncoated. Thus, the anode 300 may comprise a coated section304 which contains the coating 302, and an uncoated section 308 thatcomprises the anode electrode sheet 306 and protrudes from the coatedsection 304. The coated sheet material may then be slit alongalternating edges of the coated sections, resulting in a continuouselectrode material with exposed uncoated foil extended a specific widthfrom the coated area on one edge of the electrode.

FIG. 4 shows an example cathode 400 that may be included in theelectrode stack 500, shown in FIG. 5. Cathode 400 may also be referredto as positive electrode 400, in some examples. In one example, thecathode 400 may be similar in size and configuration to anode 300 (itmay comprise similar dimensions and may be partially covered with acoating). However, in other examples, the cathode 400 may have adifferent size, shape, etc., than the anode. Furthermore, the cathode400 is comprised of different materials than the anode 300. Inparticular, the cathode 400 may include a mixture of specially preparedLithiated Iron-Phosphate powder or Lithiated Metal-oxide powder,conductive carbon and polymeric binder. Specifically, the cathode 400may comprise a cathode electrode sheet 406 coated in a cathode coating402. The cathode electrode sheet 406 may also comprise a metallic foilcurrent collector substrate, similar to the anode electrode sheet 306 ofthe anode 300, but the coating 402 may comprise the different mixture ofspecially prepared powder. In particular, the cathode coating 402 maycomprise an electrochemically active cathode material such as themixture of specially prepared Lithiated Iron-Phosphate powder orLithiated Metal-oxide powder, conductive carbon and polymeric binderreferenced above. Thus, the cathode 400 may be prepared in a similarfashion as the anode 300, except that the coatings of the anode andcathode are different. Similar to the coating on anode 300, the coating402 may be applied over a specific portion of the electrode sheet 406,such as over a specific width of the electrode sheet 406, but not all ofthe sheet 406, such that at least a portion of the sheet 406 may remainuncoated. Thus, the cathode 400 may comprise a coated section 404 thatcontains the coating 402, and an uncoated section 408 that comprises theelectrode sheet 406. The coated sheet material may then be slit alongalternating edges of the coated sections, resulting in a continuouselectrode material with exposed uncoated foil extended a specific widthfrom the coated area on one edge of the electrode.

Thus, an uncoated portion of the electrode sheets 306 and 406 may extendbeyond and protrudes from the coatings 302 and 402. As discussed ingreater detail herein, the protruding portions of the electrode sheets306 and 406 may be trimmed down to narrower tabs. After trimming, thesenarrowed, cut uncoated electrode areas may be referred to as electrodetabs (as will be described in greater detail herein). Thus, the trimmedelectrode sheets 306 and 406 may be referred to as electrode tabs 212,216, 220, and 224.

Thus, the continuous rolls of coated, calendered, and slit electrodes300 and 400, may be stamped to desired dimensions using a normalstamping process, such as a steel ruled die or a closeclearance-stamping die. The stamped electrode shape may also be createdby laser cutting. In the prior art prismatic cells, each of the firstand second electrodes would have identical foil tabs remaining afterstamping (see FIG. 1), such that when stacked into a cell electrodestack, the individual foil tabs 102 of the first electrode would allalign in a single position relative to one corner of the electrodestack. All the stamped foil tabs 104 of the second electrode wouldlikewise all align together at a different single position relative tothe electrode stack corner.

Referring now to FIGS. 2A and 2B, as an improvement over theabove-mentioned prior art, the presently disclosed battery cell system.The continuous rolls of coated calendered and slit electrode materialsare stamped to desired dimension using stamping techniques, but each ofthe cathodes and anodes, 300 and 400 respectively, are stamped into twodifferent electrode dimensions, differing in the position of theremaining foil tab, resulting in two different stamped cathodes 202 and204 and two different stamped anodes 206 and 208. The stamped, cathodes202 and 204 may comprise electrode tabs 212 and 216, respectively. Thus,first cathode 202 may comprise a first cathode tab 212, and the secondcathode 204 may comprise a second cathode tab 216. Similarly, the firstanode 206 may comprise a first anode tab 220 and the second anode 208may comprise a second anode tab 224. As described in greater detailherein, the cathodes 202 and 204 and the anodes 206 and 208 may bestacked to form an electrode stack (e.g., the electrode stack 500 shownin FIG. 5). In particular, up to 150 of the electrodes (e.g., cathodes202 and 204 and/or anodes 206 and 208) may be stacked together to formthe electrode stack. When stacked, the electrodes may be aligned withone another such that the ends of the electrodes are aligned. Thus,first ends 201, 205, 211, and 215 of the electrodes 202, 204, 206, and208 may be aligned, and second ends 204, 207, 213, and 217 may bealigned. However, the tabs 212, 216, 220, and 224 may be laterallyoffset from one another when the electrodes are stacked, and thus, thetabs 212, 216, 220, and 224 may not overlap with one another.

As described above, the cathode tabs 212 and 216 may extend from thecathode electrode sheet 406 that has been cut down to the exampledimensions shown in FIG. 2A. Thus, the cathode tabs 212 and 216 may havea similar (e.g., equivalent) composition, and may have a similar (e.g.,equivalent) size, shape, and/or geometry, except that they are laterallyoffset from one another when the cathodes 202 and 204 are aligned withone another. Said another way, the protruding electrode sheet 306 of thecathodes 202 and 204 may be cut differently, such that their resultingcathode tabs, 212 and 216 respectively, are offset from one another, anddo not overlap when stacked as shown in FIG. 5. The cathodes 202 and 204may be aligned with another when stacked in the electrode stack (e.g.,electrode stack 500 shown in FIG. 5) by aligning first ends 201 and 205of the cathodes 202 and 204, respectively. As shown in the example ofFIG. 2A, the tabs 212 and 216 may be positioned closer to the first ends201 and 205 of the cathodes 202 and 204, respectively, than the secondends 203 and 207. Offsetting groups of anode tabs as well as cathodetabs allows the thickness of the tab stacks to be reduced when comparedto previous cell stacks in which the electrode tabs of like charge arealigned. Reducing the thickness of the tab stack allows the energy usedto weld the tab stacks to be reduced, in turn. As a result, thelikelihood of cell stack degradation (e.g., unwanted deformation,melting, etc.,) caused by increased welding intensity may be reduced, ifdesired. As a result, the size of the battery system may be increasedwithout unduly increasing the thickness of the tab stacks above anundesirable value.

Thus, cathode tab 212 may be spaced away from the first end 201 of thecathode 202 by a distance defined by a first tab offset 210. Similarly,the cathode tab 216 may be spaced away from a first end 205 of thecathode 204 by a distance defined by a second tab offset 214. However,the second tab offset 214 may be greater (e.g., a greater distance) thanthe first tab offset 210. In this way, the tab 216 of the cathode 204may be spaced a greater distance away from the first end 205 of thecathode 204, than the cathode tab 212 of the cathode 202 that is spacedfrom the first end 201 of the cathode 202. In particular, the second taboffset may be sized such that the tab 216 does not overlap any of thecathode tab 212 when the cathodes 202 and 204 are aligned with oneanother by aligning their first ends 201 and 205, and second ends 203and 207 with one another.

FIG. 2B shows a similar electrode tab spacing to the cathode tab spacingshown in FIG. 2A, except that FIG. 2B shows the electrode tab spacingfor the anodes 206 and 208. Thus, anode tabs 220 and 224 of the anodes206 and 208, respectively may have a similar (e.g., equivalent) size,shape, and/or geometry as the cathode tabs 212 and 216, except thatunlike the tabs 212 and 216 of the cathodes 202 and 204, the anode tabs220 and 224 of the anodes 206 and 208 may be spaced closer to the secondends 213 and 217 of the anodes 206 and 208 than first ends 211 and 215.

Thus, electrode tab 220 may be spaced away from the second end 213 ofthe anode 206 by a distance defined by a first tab offset 218.Similarly, the anode tab 224 may be spaced away from a second end 217 ofthe anode 208 by a distance defined by a second tab offset 222. However,the second tab offset 222 may be greater than the first tab offset 218.In this way, the tab 224 of anode 208 may be spaced a greater distanceaway from the second end 217 of the anode 208, than the tab 220 of theanode 206 is spaced from the second end 213 of the anode 206. Inparticular, the second tab offset 222 may be sized such that the tab 224does not overlap any of the tab 220 when the anodes 206 and 208 arealigned with one another by aligning their first ends 211 and 215, andsecond ends 213 and 217 with one another.

When the tabs are offset, lateral sides 250 of the offset tabs arespaced away from one another such that they are laterally separated.Furthermore, the top sides 252 of the tabs shown in FIGS. 2A and 2B havea similar height. However, in other examples, the top sides 252 of thetabs may have non-equivalent heights. Furthermore, in other examples,the first group of anode tabs may be offset from the second group ofanode tabs by a different amount than the offset between the groups ofcathode tabs.

During the electrode stacking process the two different cathodes 202 and204 and two different anodes 206 and 208 may be alternatively stackedand may be separated by insulating porous separator material. Thelateral offset between the stamped tabs of the same polarity electrodesis determined from the sum of the tolerances for stamping width andposition and the stacking position tolerance of each electrode, suchthat a small gap may be maintained between the electrode tabs of eachtype.

Referring now to FIG. 5, it shows the battery cell system 550 includingthe electrode stack 500 and the structural frame 501. The battery cellsystem 550 may also include a protective housing such as the laminatepouch 1200, shown in FIG. 12 and discussed in greater detail herein.FIG. 5 also shows the cathodes 202 and 204 and the anodes 206 and 208forming an electrode stack 500. Although the electrode stack 500 mayinclude the first and the second cathodes 202 and 204, respectively,and/or the first and the second anodes 206 and 208, respectively, in oneexample. It will be appreciated that in other examples, the electrodestack 500 may include more than two anodes and/or cathodes.

The electrodes may be held in place by a structural frame 501. Thus,when stacked, the tabs 212, 216, 220, and 224 of the electrodes 202,204, 206, and 208 may form four distinct groups of tabs, each of thegroups comprising the same type of electrode. However, in some examples,the foil tabs may be rearranged to any desirable order. Thus, a firstelectrode tab group 502 may comprise the tab 212 of the first cathode202, the second electrode tab group 504 may comprise the tab 216 of thesecond cathode 204, the third electrode tab group 506 may comprise thetab 220 of the first anode 206, and the fourth electrode tab group 508may comprise the tab 224 of the second anode 208. Each of the groups502, 504, 506, and 508 may comprise a plurality of the respective typeof electrode tab, in some examples. Further, in some examples, each ofthe groups may comprise the same number of electrode tabs. However, inother examples, the groups may comprise different numbers of electrodetabs. For instance, up to 150 electrodes may be stacked in the electrodestack 500. However, since the stack includes two different cathode tabgroups offset from one another and two different anode tab groups offsetfrom another, the number of tabs in each of the groups may be reducedwhen compared to approaches where all of the cathode tabs are alignedwith one another and all of the anode tabs are aligned with one another.

In further examples, more than two offset anode and/or cathode tabs maybe used in the electrode stack. Thus, more than two offset groups ofpositive and more than two offset groups of negative electrodes may beused in the electrode stack. By increasing the number of offset tabsthat are utilized in the electrode stack, the number of electrodes thatmay be included in the stack may be increased.

Assembling the electrode stack 500, may include utilizing a specializedstacking machine, in one example. The specialized stacking machineincludes a continuous sheet of porous separator material that is ‘Z’folded around the alternating stacked electrodes (e.g., cathodes andanodes), resulting in a rectangular or prismatic shape electrode stack500 of alternating cathodes and anodes with four distinct groups of foiltabs extending beyond the edges of the separator on a single edge of thestack or from opposing sides of the electrode stack. As an example,electrode stack 500 may be wrapped in porous separator material afterZ-wrapping the alternating electrodes. The porous separator materialallows the anodes and the cathodes to be separated to reduce thelikelihood of unwanted interaction (e.g., short circuit) between theanodes and cathodes while allowing the transportation of ionic chargecarriers. It will be appreciated that other manufacturing techniques forthe electrode stack 500 have been contemplated.

After stacking, as shown in FIG. 5, the tabs of the tab groups 502, 504,506, and 508, may be trimmed, shaped, bent, folded, etc., to a desiredshape (e.g., a final shape), an example of which is shown in FIG. 6.FIG. 6, shows the electrode stack 500 after removal from the stackingmachine, where the electrode stack 500 is placed in the structural frame501 (e.g., holding fixture) and the extending tab groups 502, 504, 506,and 508 are shaped and trimmed to a desired shape (e.g., final shape)and dimension they may have after welding of a cell extension tab. Asshown in FIG. 6, the trimmed and shaped tab groups may be referred toherein as shaped tab groups 602, 604, 606, and 608. Thus, the tab groups602, 604, 606, and 608, are the tab groups 502, 504, 506, 508 that havebeen trimmed and shaped to a desired shape prior to welding. Thenegative electrode groups 602 and 604 including the negative electrodetabs may be referred to collectively as the cathode tabs 612, and thepositive electrode groups 606 and 608 may be referred to collectively asthe anode tabs 614. In some cases, a small ultrasonic pre-weld may beemployed to hold the tabs in the desired shape for consolidation andextension tab welding.

As shown in FIG. 6, the tab groups 502, 504, 506, and 508 may be trimmedsuch that the resulting tabs 612 and 614 may include vertical weldingsurfaces 603 and 605, respectively, which may be welded directly toextension tabs as shown and described in greater detail herein withreference to FIG. 7.

FIG. 6 also shows a front side 650, a backside 652, a top side 654, abottom side 656, a first lateral side 658, and a second lateral side 660of the battery cell system 550. The structural frame 501 may partiallyenclose the electrode stack 500. Specifically, the structural frame 501extends down the front side 650, the backside 652, the first lateralside 658, and the second lateral side 660 of the system. In this way,the structural frame 501 may provide structural reinforcement to thebattery cell system 550.

Turning to FIG. 18, a general stacking sequence for forming an electrodestack 1800 in a battery cell system 1850, is illustrated. The batterycell system 1850 may be an example of the battery cell system 550, shownin FIGS. 2A-17. The electrode stack 1800 may be arranged according tothe following the pattern: separator material 1802/first electrode1804/separator material 1802/second electrode 1806/separator material1802/third electrode 1808/separator material 1802/fourth electrode 1810and so one and so forth. In this non-limiting example, elements 1804,1806, 1808, and 1810 may correspond to any of the first and secondpositive and negative electrodes shown in FIGS. 2A and 2B. However,other stacking sequences have been contemplated. Furthermore, it will beappreciated that the cell stacking pattern shown in FIG. 18 may berepeated as many times as desired. In some examples, the pattern may berepeated between 20 and 60 times. As an example, indicated by thebottom-most separator material 1802 (bottom and top distinguished byarrow adjacent to electrode stack), the stack may be started at the topwith a layer of separator material and ended at the bottom with a lower(e.g., final) layer of separator material.

As an example, with reference to FIG. 18, a stacking sequence which maybe repetitively employed is: separator/first anode/separator/firstcathode/separator/second anode/separator/second cathode. However, asmentioned above other stacking sequence may be employed. Additionally,as an example, one or more stacking sequences may be used throughout thestack. As a further example, after stacking and repeating the stackingsequence or sequences a number of times, a layer of separator materialmay be used such that the stack begins and ends with layers of separatormaterial. As a further example, after stacking, the trailing edge ofseparator may be taped in place to maintain its position duringsubsequent cell manufacturing steps.

Referring now to FIG. 7, after tab shaping and trimming each pair of atleast two tab groups (for example, 612 and 614 of FIG. 6) may be weldedto a first extension tab 702 and second extension tab 704, the width ofthe first and second extension tabs may be at least equal to twice theelectrode tab width plus the gap between the two tab groups, 612 and614, in one example. Two separate ultrasonic welds are employed toconsolidate the two electrode tab groups to the single extension tab.The two welds may be accomplished simultaneously with a single weldinghorn, in one instance. This welding may be performed separately on boththe two groups of anode tabs and on the anode extension tab and also onthe two groups of cathode tabs and on the cathode extension tab. As anexample, the two groups of anode tabs 614 may be welded to an anodeextension tab 704, and the two groups of cathode tabs 612 may be weldedto a cathode extension tab 702. The extension tabs 702 and 704 allowdifferent groups of offset tabs to be electronically coupled.

In some examples, the tabs 612 and 614 may be sandwiched between theextension tabs 702 and 704, and electrode tab supports 706, and 708,respectively. However, in other examples, the tabs may be directlywelded to the extension tabs without the electrode tab supports. Inother examples, the respective tab groups 602 and 604, shown in FIG. 6,and then the tab groups 606 and 608, shown in FIG. 6, may be welded toextension tabs 702 and 704, shown in FIG. 7. Such a process may be usedto consolidate the tab groups before adding the tab supports 706 and 708and may provide a more robust electrode assembly.

The electrode tab supports 706 and 708 increase the structural integrityof the tab assembly thereby reducing the likelihood of tab damageoccurring during battery use and/or manufacturing. As a result, thedurability of the battery cell system is increased. The electrode tabsupports 706 and 708 each include a slit 710 and 712, respectively,through which the extension tabs 702 and 704 may extend, in theillustrated example. However, other electrode tab support profiles havebeen contemplated. Additionally, in one example, the electrode tabsupports 706 and/or 708 may include an electrically insulating polymericmaterial 714. The electrically insulating polymeric material 714 may bedesigned to provide electrical isolation between the extension tabs 702and 704 and components such as a protective housing, described ingreater detail herein. Further, in some examples, the electrode tabsupports 706 and 708 may be integrally formed with the protectivehousing or are directly physically coupled to the protective housing.

Additionally, in one example, the cathode tabs 612 may include analuminum material and the anode tabs 614 may include a nickel platedcopper material. However, additional or alternative material may beincluded in the anode and/or cathode tabs, in other examples.

Referring now to FIG. 8, after welding of the extension tabs, astructural frame 501 containing the electrode stack is assembled. In oneexample, in a cell configuration having both positive and negative tabson a single cell face, there may only be a single molded frame assemblyon that face. In another example, if the tabs extend from opposing sidesof the electrode stack, then two molded frame assemblies may be used.The structural frame 501 may include at least one support 804 (e.g.,polymer support). In the illustrated example, the support 804 has asubstantially triangular cross section with chamfered edges, to matchthe resulting shape of the laminate pouch packaging. However, otherprofiles of the support 804 have been contemplated. Additionally, thesupport 804 includes two slots 805 and 807 sized to allow the extensiontabs 702 and 704 to pass through the central region of the support. Thestructural frame 501 may be fabricated in two matching halves which arethen assembled onto the tabbed side of the cell by snap fitting or pressfitting the two molded frame halves together, in one example.Furthermore, the support 804 may be injection molded, in one example.Additionally, the support 804 has a triangular cross-section in a Z-Yplane, in the illustrated example. Thus, the support 804 may taper inthe vertical direction. However, other shapes of the support 804 havebeen contemplated and may be used, in other examples. For instance, thesupport 804 may have rectangular cross-section or the support mayinclude curved (e.g., convex or concave) sections. Furthermore, thesupport 804 may be attached (e.g., welded, adhesively bonded,mechanically coupled, combinations thereof, etc.,) to a base 806 of thestructural frame 501.

Referring next to FIG. 9, it shows the structural frame 501 (e.g.,internal box) assembled and providing mechanical separation of the tabsand electrode stack from the internal surfaces of the laminate pouchpackaging material, thereby protecting the pouch from mechanical damageand loss of electrical isolation due to impact, vibration or shockduring handling or subsequent environmental exposure in the batteryapplication environment. The structural frame may be fabricated in twoseparate halves, 904 and 906, by injection molding and may be assembledonto the welded electrode stack by press fitting or snap fitting.Additionally, a further enhancement of the structural frame may includea reduced thickness area 908 on one face 909 of the structural frame501, thereby creating a recessed groove to provide mechanical relief toa heat sealed seam of the laminate pouch which may be applied in thenext assembly step. In one example, the structural frame 501 may beinjection molded. However, other frame manufacturing techniques havebeen contemplated.

Structural frame 501 may then be packaged and/or vacuum sealed within aprotective housing. In one example, the protective housing may be alaminate pouch, such as the laminate pouch 1200 shown in FIG. 12, withan internal protective structure with a recessed seam relief groove, asdescribed above. However, other types of protective housing have beencontemplated, such as a housing that has a greater rigidity.

An example of a laminate pouch 1900 is shown in FIG. 19. It will beappreciated that the laminate pouch 1900 is an example of the previouslydescribed laminate pouch 1200 included in the cell battery system 550.The laminate pouch 1900, shown in FIG. 19, may include at least twolayers and, in some examples, four functional layers to create a heatsealable laminate with at least one metallic layer which reduces (e.g.,prevents) moisture ingress into the finished electrochemical cell,having a non-aqueous electrolyte. The inner most layer 1902 may be aheat sealable polyolefin, such a polypropylene, bonded to an aluminumlayer 1904 which may be bonded to another polymer layer 1906 (e.g., anylon layer) which in turn may be bonded to the external layer 1908(e.g., a polyethylene terephthalate (PET) layer). As an example, thelayers 1902, 1904, 1906, and 1908 may be rearranged as desired based onend-use design goals. The laminate pouch 1900 may be included in abattery cell system 1950. It will be appreciated that the battery cellsystem 1950 may be an example of the battery cell system 550, shown inFIGS. 2A-18. The laminate pouch 1900 may include one or more walls thataccommodate expansion during electrolyte activation, in one example.Further, in such an example, the walls of the laminate pouch may besubstantially flat after electrolyte activation and bent inward prior toelectrolyte activation. In this way, the pouch may accommodate expansionto reduce the likelihood of pouch and/or cell damage.

Turning now to FIG. 10, as a further example, assembling the batterycell system 550 may optionally include first assembling the structuralframe 501 around the exterior of the welded electrode stack assembly inorder to protect the electrode stack edges from mechanical damage duringassembly and use as well as to protect the electrode stack edges fromexternal pressure (e.g., a pressure of at least 14.6 pounds per squareinch (psi)) created when the cell assembly is vacuum sealed. Theinternal frame may include at least a protective frame placed around thewelded tab area of the electrode stack. The top side of the structuralframe may have a substantially triangular cross sectional shape andtapered edges 1002, 1004 at the ends to match with the shape of thefolded pouch laminate packaging. Optionally the structural frame 501 maybe extended to prevent the edges and corners of the electrode stack frommaking direct contact with the internal surface of the pouch laminatematerial, thereby preventing loss of internal electrical isolation bymechanical damage to the inner heat sealable polymer layer and exposingthe Aluminum layer to electrical contact with the electrochemicallyactive electrodes.

In one example, the internal structural frame may be fabricated in twomatching halves with a flexible gap between each frame half, shown inFIGS. 9 and 10. The reduced thickness area 908 of the structural frame501 allows the finished cell and electrode stack to be compressed in thenormal thickness direction during the cell's electrochemical activation,formation and degassing processes. This compression being applied as ameans to eliminate gas bubbles between the electrode and separatorsurfaces which form as a byproduct of the cell's electrochemicalformation processes, such as anode SEI formation, reaction with residualmoisture in the cell and/or other parasitic chemical reactions whichgenerate gaseous byproducts. The flexible gap further allows the cellthickness to increase/decrease during cell charging and discharging dueto electrode swelling caused by the changing state of charge. Thestructural frame (e.g., internal fabricated support frame) may befabricated by injection molding a chemically compatible polymer such aspolypropylene, polyethylene, polybutylene terephthalate (PBT), and/orpolyethylene terephthalate (PET), for example.

Turning now to FIG. 11, as an example, in order to accommodate electrodestack swelling during cell electrolyte activation, formation, and use,the vertical side walls 1104 of the structural frame 501 and/orprotective housing, discussed in greater detail herein, may be taperedinward toward the center-line 1110 of the cell, allowing extra materialto accommodate cell expansion and retraction. The extra material reducesthe likelihood of wrinkling and cracking in the battery cell system. Asthe cell swells, indicated at 1106, during the normal cycling of thebattery, the extra material may provide strain relief so as not todamage the central seam. The electrode stack and frame assembly may thenbe packaged within the laminate pouch. As a further example, theabove-mentioned feature of tapered-inward sides of the structural frame501 may be used in order to relieve pressure on other edges or faces ofthe battery. Thus, other edges or faces of the battery may havetapered-inward sides.

Turning to FIG. 12, the battery cell system includes a protectivehousing in the form of a laminate pouch 1200, in the illustratedexample. However, as previously discussed other suitable types ofprotective housings have been contemplated.

As shown in FIG. 12, the laminate pouch 1200 may be formed into arectangular cross sectional shape and one section (e.g., end) may befolded and heat sealed. As such, a heat seam 1202 extends (e.g.,vertically extends) down the laminate pouch, in the illustrated example.In this way, a closed end of the laminate pouch may be formed.Furthermore, the heat seam 1202 may be aligned with the reducedthickness area 908 in the structural frame 501, shown in FIG. 10. Inthis way, the heat seam 1202 may be mated with the reduced thicknessarea 908, in one example. However, it will be appreciated that the heatseam 1202 may be positioned in other locations, in other examples.

Additionally, a solid rectangular sizing fixture 1206, having the samedimensions as the electrode stack, may be placed inside the laminatepouch to maintain a desired rectangular shape while one end may befolded and heat sealed, in some examples.

One example of an assembly sequence for a laminate pouch may be asfollows: the laminate pouch material may be taken from a continuous rolland first rolled into tubular form with an overlapping section of 2 to20 mm wide. As an example, the overlapping section may be 10 mm wide.The overlapping section may be heat sealed using flat heating bars andfolded flat with respect to the unsealed surface.

The pouch folding may include, in one example, displacing a triangularshaped area on each of the two narrow sides of the pouch whilecompressing the long faces of the pouch perpendicular direction withrespect to the pouch's narrow side walls. Additionally, the pouch 1200may be selectively heat sealed along a narrow width adjacent to thesidewall edges of the pouch package. The center area may be leftunsealed at this step to allow electrolyte filling during futureassembly steps, in some examples.

Turning now to FIGS. 13A and 13B, after folding and heat sealing thebottom closed end of the laminate pouch 1200, the rectangular sizingfixture 1206 may be removed and the electrode stack and molded plasticframe assembly may be inserted with tabs facing away from the closed endof the pouch package. The corner triangular folds may be accomplished insimilar fashion as were the bottom closed end triangular folds. The topopen end may be compressed and the pouch may be heat sealed both to theelectrode tab supports 706 and 708 and to the opposing face of thepouch, creating a seal at the top tab end of the cell. A fill port mayalso be incorporated into this concept. This feature can be integratedwith the injection molded protective frame or as a separate part fusedto the pouch material or frame. The surrounding area of the structuralframe may be heat sealed to the internal polymer layer of the pouch,creating a leak tight seal. Additionally, an untrimmed end 1306 of thelaminate pouch 1200 may be employed for cell filling and gas formationcollection.

FIG. 14 shows an additional view of the laminate pouch 1200 with theadditional untrimmed end 1306 of laminate pouch.

FIG. 15 shows an alternate view of the electrode welded stack before theaddition of the structural frame or the addition of a protective housing(e.g., laminate pouch) before a structural frame or sizing fixture hasbeen added.

Turning now to FIG. 16, a port 1602 (e.g., fill port) in the laminatepouch 1200 may be molded with internal or external threads and used forelectrolyte filling and/or degassing of the cell during the formationprocess, thereby reducing the quantity of pouch material used inmanufacturing in comparison to the current formation process. In someinstances, incorporation of the filling/degassing port may reduce theamount of pouch material used for forming of the battery cell by 40%(compared to forming the battery cell without a filling/degassing port).The current formation process uses an integral gas volume formed withextra length of pouch material, creating an extra internal void volumeto accommodate gasses generated during the initial cell formationprocess.

Turning to FIG. 17, the above-mentioned fill port may incorporate avent/rupture disc 1702 in the laminate pouch 1200 which may help tomanage pressure relief, thereby providing controlled venting underoperating conditions or extreme conditions in which the cell has beenrun or handled outside normal operating conditions (e.g., physicaldamage to battery, exposure to extreme heat etc.).

With reference to FIG. 17, after formation, the cell may be vacuumdegassed and sealed. In the current process the extra pouch material maybe trimmed off during a vacuum sealing step and discarded. The cell maybe vacuum degassed through the integrated fill port during thisdegassing step. After degassing the fill port may be sealed by severalmethods, such as a heat sealed plug or threaded plug. As an example,further enhancement to cell safety under abusive conditions may be madeand a pressure relief vent is installed in the fill port sealing plug.The fill port may have a vent cap plug that will rupture or open at aspecified pressure to control the rate of gas ejection from the cell,decreasing the probability of explosion or fire during exposure toabusive conditions. Adding a plug or disc may in some instancesincorporate the sealing methods mentioned above, not limited to heatsealing or threading. As an example, controlled venting may alsoincorporate a scored or coined slit on the pouch to rupture before heatseal failure. As an example, scoring or slitting the pouch may be addedto any desirable location on the pouch.

It should be understood that the figures show example configurationswith relative positioning of the various components. If shown directlycontacting each other, or directly coupled, then such elements may bereferred to as directly contacting or directly coupled, respectively, atleast in one example. Similarly, elements shown contiguous or adjacentto one another may be contiguous or adjacent to each other,respectively, at least in one example. As an example, components layingin face-sharing contact with each other may be referred to as inface-sharing contact. As another example, elements positioned apart fromeach other with only a space there-between and no other components maybe referred to as such, in at least one example. As yet another example,elements shown above/below one another, at opposite sides to oneanother, or to the left/right of one another may be referred to as such,relative to one another. Further, as shown in the figures, a topmostelement or point of element may be referred to as a “top” of thecomponent and a bottommost element or point of the element may bereferred to as a “bottom” of the component, in at least one example. Asused herein, top/bottom, upper/lower, above/below, may be relative to avertical axis of the figures and used to describe positioning ofelements of the figures relative to one another. As such, elements shownabove other elements are positioned vertically above the other elements,in one example. As yet another example, shapes of the elements depictedwithin the figures may be referred to as having those shapes (e.g., suchas being circular, straight, planar, curved, rounded, chamfered, angled,or the like). Further, elements shown intersecting one another may bereferred to as intersecting elements or intersecting one another, in atleast one example. Further still, an element shown within anotherelement or shown outside of another element may be referred as such, inone example.

FIG. 20 shows a method 2000 for manufacturing a battery cell system. Themethod 2000 may be used to manufacture the battery cell systemsdescribed above with regard to FIGS. 2A-19. However, in other examples,the method may be used to manufacture other suitable battery cellsystems. Furthermore, the method 2000 may be stored as instructions inmemory (e.g., non-transitory memory) executable by a processor.

At 2001 the method includes forming an electrode stack with offset anodetabs and offset cathode tabs. It will be appreciated that the electrodestack may include alternating cathodes and anodes with separator sheetspositioned there between, in some examples. Specifically, the anodes andcathodes may be formed in an electrode stack with the following stackingsequence; a first anode, a first layer of porous separator material, afirst cathode, a second layer of porous separator material, etc. Formingthe electrode stack may include steps 2002-2004.

At 2002 the method includes forming a plurality of anodes with aplurality of anode tabs, where the plurality of anode tabs include afirst group of anode tabs laterally offset from a second group of anodetabs.

Next at 2004 the method includes forming a plurality of cathodes with aplurality of cathode tabs, where the plurality of cathode tabs include afirst group of cathode tabs laterally offset from a second group ofcathode tabs. Laterally offsetting groups of cathode tabs as well asgroups of anode tabs allows the thickness of the tabs to be reduced whencompared to cell stack with aligned tabs. Therefore, welding energyneeded to weld the groups of tabs may be reduced. Consequently, thelikelihood of degradation (e.g., melting, deformation, etc.,) of theelectrode tabs (e.g., anode and cathode tabs) during welding is reduced.

At 2006 the method includes welding a first extension tab to the firstgroup of anode tabs and the second group of anode tabs. Next at 2008 themethod includes welding a second extension tab to the first group ofcathode tabs and the second group of cathode tabs.

Additionally, in some examples, the method may include steps 2010, 2012,2014, and/or 2016. At 2010 the method includes attaching a firstelectrode tab support to the first group of anode tabs and the secondgroup of anode tabs and at 2012 the method includes attaching a secondelectrode tab support to the first group of cathode tabs and the secondgroup of cathode tabs.

At 2014 the method includes placing the electrode stack in a structuralframe. The structural frame may at least partially surround theelectrode stack. Further, in one example, the structural frame mayinclude openings allowing the first and second support tabs to extendthere through. Additionally, the structural frame may be molded from apolymeric material, in one example.

At 2016 the method includes placing the structural frame and theelectrode stack within a protective housing. In one example, theprotective housing may be a laminate pouch and therefore, the method mayinclude in such an example, folding a laminate pouch around theelectrode stack and the support frame and heat sealing the laminatepouch. In one example, subsequent to folding and heat sealing thelaminate pouch, the pouch may be degassed via a degas port. Afterdegassing the degas port may be sealed. In this way, unwanted gas may beremoved from the system, thereby reducing the size of the protectivehousing. Consequently, the compactness of the battery cell system may beincreased.

The invention will further be described in the following paragraphs. Inone aspect, a battery cell system is provided that includes an electrodestack including a first anode with a first anode tab, a second anodewith a second anode tab laterally offset from the first anode tab, afirst cathode with a first cathode tab, and a second cathode with asecond cathode tab laterally offset from the first cathode tab.

In another aspect, a method for manufacturing a battery cell system isprovided. The method includes forming a plurality of anodes with aplurality of anode tabs, where the plurality of anode tabs include afirst group of anode tabs laterally offset from a second group of anodetabs, forming a plurality of cathodes with a plurality of cathode tabs,where the plurality of cathode tabs include a first group of cathodetabs laterally offset from a second group of cathode tabs, welding afirst extension tab to the first group of anode tabs and the secondgroup of anode tabs, and welding a second extension tab to the firstgroup of cathode tabs and the second group of cathode tabs. In oneexample, the method may further include attaching a first electrode tabsupport to the first group of anode tabs and the second group of anodetabs and attaching a second electrode tab support to the first group ofcathode tabs and the second group of cathode tabs. In another example,the method may further include placing the plurality of cathodes andanodes in at least one of a structural frame and a protective housing atleast partially surrounding the plurality of cathodes and anodes.

In another aspect, an electrochemical cell is provided that comprises aplurality of first negative electrodes comprising first negativeelectrode tabs, a plurality of second negative electrode comprisingsecond negative electrode tabs, wherein the second negative electrodetabs are offset from the first negative electrode tabs, a plurality offirst positive electrodes comprising first positive electrode tabs, anda plurality of second positive electrodes comprising second positiveelectrode tabs.

In another aspect, an electrochemical cell is provided that includes afirst positive electrode and a second positive electrode forming apositive electrode group, and a first negative electrode and a secondnegative electrode forming a negative electrode group, wherein eachelectrode is separated by a layer of porous separator material, and eachelectrode has a tab width and offset such that no tabs of differentelectrodes overlap and, the at least two electrodes of the positiveelectrode group are welded together and the at least two electrodes ofthe negative electrode group are welded together.

In another aspect, an internal frame for an electrochemical cell isprovided that includes an electrode tab support, the electrode tabsupport comprising two slots for receiving an anode and a cathode of theelectrochemical cell, wherein the electrode tab support prevents lateralmovement of the anode and cathode.

In another aspect, an electrochemical cell is provided that includes astack of aligned electrodes, the stack comprising at least four groupsof electrode tabs offset from one another.

In any of the aspects or combinations of the aspects, the electrodestack may further comprise a porous separator positioned between each ofthe first and second anode and the first and second cathode.

In any of the aspects or combinations of the aspects, the battery cellsystem may further include a first extension tab welded to and laterallyextending between the first and second anode tabs.

In any of the aspects or combinations of the aspects, the battery cellsystem may further include a second extension tab welded to andlaterally extending between the first and second cathode tabs.

In any of the aspects or combinations of the aspects, the battery cellsystem may further include an electrode tab support, wherein theelectrode tab support is fitted over one or more of the first and secondanodes and/or cathodes and the first and second extension tabs andprovides mechanical support for the first and second extension tabs.

In any of the aspects or combinations of the aspects, the electrode tabsupport may include an electrically insulating polymeric material andprovides electrical isolation between the first and/or extension tabsand a protective housing.

In any of the aspects or combinations of the aspects, the electrode tabsupport may include a first slit and a second slit for receiving thefirst and second extension tabs, where the first and second extensiontabs extend through the first slit and the second slit in the electrodetab support.

In any of the aspects or combinations of the aspects, the battery cellsystem may include a structural frame at least partially surrounding thefirst and second anodes and the first and second cathodes.

In any of the aspects or combinations of the aspects, the electrode tabsupport may be integrally formed within a protective housing, or isdirectly physically coupled to the protective housing.

In any of the aspects or combinations of the aspects, the structuralframe may include one or more walls that are flexible and are bentinwards towards the electrode stack, such that the one or more wallsaccommodate expansion during electrolyte activation.

In any of the aspects or combinations of the aspects, the structuralframe may include one or more faces with a recessed area of reducedthickness mated with a heat seam of a protective housing.

In any of the aspects or combinations of the aspects, the battery cellsystem may further include a protective housing includes a portreceiving an electrolyte and/or venting gasses.

In any of the aspects or combinations of the aspects, the negativeelectrodes and the positive electrode tabs may be offset from oneanother.

In any of the aspects or combinations of the aspects, the electrodes maybe the same size, such that when stacked, the edges of the electrodesare aligned with one another, except for the tabs.

In any of the aspects or combinations of the aspects, the tabs may beoffset when the electrodes are stacked to form an array.

In any of the aspects or combinations of the aspects, theelectrochemical cell may further include a structural frame throughwhich the electrode tabs extend.

In any of the aspects or combinations of the aspects, the structuralframe limits lateral movement of the electrode tabs.

In any of the aspects or combinations of the aspects, theelectrochemical cells may further comprise electrode extension tabsextending from the electrode tabs, and welded to the electrode tabs.

In any of the aspects or combinations of the aspects, the at least fourgroups of electrode tabs may be welded to two electrode extension tabs,and where each of the at least four groups of electrode tabs may only bewelded to one of the two electrode extension tabs.

In any of the aspects or combinations of the aspects, the at least fourgroups of electrode tabs may comprise at least two groups of negativeelectrode tabs and at least two groups positive electrode tabs.

In any of the aspects or combinations of the aspects, at least fourgroups of electrode tabs may comprise a vertically folded portion thatis welded to an extension tab.

In any of the aspects or combinations of the aspects, theelectrochemical cell may further comprise an injection molded frame.

In any of the aspects or combinations of the aspects, theelectrochemical cell may further comprise a multi-layered laminatepouch.

In any of the aspects or combinations of the aspects, theelectrochemical cell may further comprise a multi-use port for fillingthe electrochemical cell with electrolyte and/or degassing theelectrochemical cell.

In any of the aspects or combinations of the aspects, offset tabs ofmatching polarity may be welded to an electrode group tab and then maybe welded to an extension tab.

In any of the aspects or combinations of the aspects, the anode tab mayinclude nickel plated copper and the cathode tab may include aluminum.

In any of the aspects or combinations of the aspects, the electrode tabsupport may have a triangular cross-section.

The subject matter of the present disclosure includes all novel andnonobvious combinations and subcombinations of the various systems andconfigurations, and other features, functions, and/or propertiesdisclosed herein.

The following claims particularly point out certain combinations andsubcombinations regarded as novel and nonobvious. These claims may referto “an” element or “a first” element or the equivalent thereof. Suchclaims should be understood to include incorporation of one or more suchelements, neither requiring nor excluding two or more such elements.Other combinations and subcombinations of the disclosed features,functions, elements, and/or properties may be claimed through amendmentof the present claims or through presentation of new claims in this or arelated application. Such claims, whether broader, narrower, equal, ordifferent in scope to the original claims, also are regarded as includedwithin the subject matter of the present disclosure.

1. A battery cell system comprising: an electrode stack including; afirst anode with a first anode tab; a second anode with a second anodetab laterally offset from the first anode tab; a first cathode with afirst cathode tab; and a second cathode with a second cathode tablaterally offset from the first cathode tab; where the first anode tab,second anode tab, first cathode tab, and second cathode tab extend fromone side of the electrode stack.
 2. The battery cell system of claim 1,where the electrode stack further comprises a porous separatorpositioned between each of the first and second anode and the first andsecond cathode.
 3. The battery cell system of claim 1, furthercomprising a first extension tab welded to and laterally extendingbetween the first and second anode tabs.
 4. The battery cell system ofclaim 3, further comprising a second extension tab welded to andlaterally extending between the first and second cathode tabs.
 5. Thebattery cell system of claim 4, further comprising an electrode tabsupport, wherein the electrode tab support is fitted over one or more ofthe first and second anodes and/or cathodes and the first and secondextension tabs and provides mechanical support for the first and secondextension tabs.
 6. The battery cell system of claim 5, wherein theelectrode tab support includes an electrically insulating polymericmaterial and provides electrical isolation between the first and/orextension tabs and a protective housing.
 7. The battery cell system ofclaim 5, wherein the electrode tab support includes a first slit and asecond slit for receiving the first and second extension tabs, where thefirst and second extension tabs extend through the first slit and thesecond slit in the electrode tab support.
 8. The battery cell system ofclaim 5, wherein the electrode tab support is integrally formed within aprotective housing, or is directly physically coupled to the protectivehousing.
 9. The battery cell system of claim 1, further comprising astructural frame at least partially surrounding the first and secondanodes and the first and second cathodes.
 10. The battery cell system ofclaim 9, where the structural frame includes one or more walls that areflexible and are bent inwards towards the electrode stack, such that theone or more walls accommodate expansion during electrolyte activation.11. The battery cell system of claim 9, where the structural frameincludes one or more faces with a recessed area of reduced thicknessmated with a heat seam of a protective housing.
 12. The battery cellsystem of claim 1, further comprising a protective housing includes aport receiving an electrolyte and/or venting gasses.
 13. A method formanufacturing a battery cell system, comprising: forming a plurality ofanodes with a plurality of anode tabs, where the plurality of anode tabsinclude a first group of anode tabs laterally offset from a second groupof anode tabs; forming a plurality of cathodes with a plurality ofcathode tabs, where the plurality of cathode tabs include a first groupof cathode tabs laterally offset from a second group of cathode tabs;welding a first extension tab to the first group of anode tabs and thesecond group of anode tabs; and welding a second extension tab to thefirst group of cathode tabs and the second group of cathode tabs; wherethe first anode tab, second anode tab, first cathode tab, and secondcathode tab extend from one side of the electrode stack.
 14. The methodof claim 13, further comprising attaching a first electrode tab supportto the first group of anode tabs and the second group of anode tabs andattaching a second electrode tab support to the first group of cathodetabs and the second group of cathode tabs.
 15. The method of claim 13,further comprising placing the plurality of cathodes and anodes in atleast one of a structural frame and a protective housing at leastpartially surrounding the plurality of cathodes and anodes.
 16. Abattery cell system comprising: an electrode stack including; a firstanode with a first anode tab; a second anode with a second anode tablaterally offset from the first anode tab; a first cathode with a firstcathode tab; and a second cathode with a second cathode tab laterallyoffset from the first cathode tab; a first extension tab welded to andlaterally extending between the first and second anode tabs; and asecond extension tab welded to and laterally extending between the firstand second cathode tabs; where the first anode tab, second anode tab,first cathode tab, and second cathode tab extend from one side of theelectrode cell stack.
 17. The battery cell system of claim 16, where theelectrode stack further comprises a porous separator positioned betweeneach of the first and second anode and the first and second cathode. 18.The battery cell system of claim 16, further comprising an electrode tabsupport, wherein the electrode tab support is fitted over one or more ofthe first and second anodes and/or cathodes and the first and secondextension tabs and provides mechanical support for the first and secondextension tabs.
 19. The battery cell system of claim 18, wherein theelectrode tab support is integrally formed within a protective housing.20. The battery cell system of claim 18, wherein the electrode tabsupport is directly physically coupled to the protective housing.